INSTALLATION GUIDE
Contents
1. BY zx RICHMOND Installation Guide Contents Page Open Differential Part Identification amp Terminology 2 Powertrax No Slip Differential Exploded View 3 Vehicle Preparation for Installation steps 1 to 5 4 Removal of Open Differential Parts steps 6 to 11 5 Preparation of Parts to be Installed steps 12 to 14 7 Assembly steps 15 to 40 8 Verification of Proper Assembly Test steps 41 to 45 17 Finish Installation steps 46 to 50 18 Thoroughly read User Manual Traction output and resulting handling characteristics of your vehicle will be modified by installation Drive carefully and use caution under all on road and off road conditions LIMITED SLIP DIFFERENTIAL PART IDENTIFICATION TERMINOLOGY Spider Gear Washer 2 Spider Gear 2 Ring Gear C Clip 2 Axle Housing Thrust Washer 2 Clutches Bearing Cap 2 Side Gear 2 Pinion Shaft Differential Case Retaining Bolt or Roll Pin 2 EXPLODED VIEW Paddle O nic addle Opening Saddle Block in Coupler Paddle Spring 8 0 Inner Pinion Shaft N N Spring 2 22 L 3 asi i gt y n e Ex V NE Outer ur c 4 d Spring 2 Sep Serna ar er Synchro Ring Slotted i is SOME Paddle Opening in Driver Driver Driver gt 2 Active Spacer2. N Active Spacer gt POWERTRAX Slotted NO SLIP TRACTION SYSTEM 1 Put transmission in gear or park and turn off engine 2 Set parking brake 3 Safeguard the vehicle from rolling 4 Safely raise vehicle and apply jack stands 6 Remove differential cover and drain fluid Clean the diff cover and housing sealing surface 7 Expose pinion shaft remove retaining bolt roll pin and shaft 8 Push both axles inward and remove both c clips Remove o rings from c clip grooves on axle shafts if present 9 Pull axles out approx 8 and remove clutch spring some may have multiple coil springs if present 10 Remove both spider gears and their thrust washers 11 Remove side gears clutches and thrust washers 12 Verify gaps in coupler teeth are positioned within gaps in synchro ring Place coupler in a vise and use an active spacer to align them if necessary 13 Apply wheel bearing grease to driver teeth and spacer 14 Apply wheel bearing grease to saddle springs amp seat in holes 15 Install couplers inside differential case ring gear side first 16 Install c clip on ring gear side axle shaft only A LEA N 7 VA NN L NT N O 7 gt i m N N A A cw X Paddle Opening
3. ga de NA a e 17 Make sure paddle opening widest gap in ring gear side synchro ring is facing out towards YOU 18 Insert the non slotted spacer into the non slotted driver Seat the spacer paddle at the missing extended tooth 19 Insert driver spacer as shown making sure spacer paddle is facing out towards you 20 Verify spacer paddle is aligned with paddle opening in synchro ring and press driver spacer down onto coupler Driver teeth should be fully engaged all the way around 21 Insert the slotted spacer into the slotted driver Seat the spacer paddle at the missing extended tooth 22 Verify paddle opening widest gap in other synchro ring is facing the back of the differential away from you Tun 23 Install slotted driver spacer making sure that paddle is pointing away from you toward rear of differential 24 Verify spacer paddle is aligned with the paddle opening in synchro ring and press down on driver spacer to seat on coupler driver teeth should be fully engaged all the way around 25 Wedge both drivers in engagement with couplers Rotate driver s side wheel forward 1 4 turn to reveal spring slot 26 Place the two inner springs inside the two outer springs 2 Compress inner spring and install spring assembly into spring slot 28 Visually inspect notches in spring slot to make sure inner spring is fully seate
4. C Clip Version BY GSROHOND Box 238 1208 Old Norris Road Liberty S C 29657 Tech Support 864 843 9275 Fax 864 843 1276 www richmondgear com
5. d check spring Tif mm YA s E Ne E q E ooo E 29 Keeping both drivers wedged in engagement with couplers rotate driver s side wheel forward 1 2 turn to reveal spring slot on other side ge 30 Compress inner spring and install the second spring assembly into the second spring slot 31 Visually inspect notches in spring slot to make sure inner spring is fully seated check spring 13 32 Check the gap between drivers using check block The narrow side of the block should fit inbetween drivers but the wider side should not fit If gap is incorrect STOP and call Powertrax Technical Support at 864 843 9275 There may be a problem with your differential case 33 Push passenger side axle shaft inward through coupler as far as it will go 34 Making sure drivers stay engaged with couplers carefully rotate driver s side wheel until c clip slot is accessible Verify c clip groove on axle is accessible through c clip slots on driver and spacer ei AAA 7 7 VA ne gt 7 b ee amp 1 h 7 p i 5 pinion shaft opening 15 35 Insert 2nd c clip through c clip slot in driver onto axle shaft pull axle shaft out to seat c clip 36 Making sure driv
6. ers stay engaged with couplers carefully rotate both wheels backwards 1 4 turn to expose pinion shaft opening 37 Feel through pinion shaft opening and verify both spacers and drivers are fully seated onto couplers Verify all 8 saddle springs are fully seated in holes 5 saddle springs 38 Keeping couplers and drivers stationary rotate case 1 4 turn forward to align pinion shaft openings 39 Using the retaining bolt roll pin as a handle insert the shaft into the differential Press hard while twisting to pass shaft by springs 40 Insert retaining bolt roll pin into case shaft Tighten retaining bolt firmly P D gt 5 Aer A WE WR UY 1 41 Put transmission in gear or park 42 Turn driver s side wheel forward and hold against driveline for steps 43 amp 44 43 Passenger side wheel should not be able to rotate in the same direction 44 After sharply turning the passenger side wheel in the opposite direction to disen gage the unit the wheel should rotate freely 45 Repeat the test for both wheels in both lt directions gt 17 HOLD 46 Install differential cover with gasket sealant 47 Add Richmond Synthetic Gear Oil 75W 140 available at your Authorized Richmond Distributor 49 Be sure transmission is in gear or park 50 Remove jack stands lower vehicle then remove b
7. ges if you are not fully familiar with these or other procedures with respect to the transmission or are uncertain as to how to proceed Have the necessary work done by a properly equipped and qualified workshop e Always be extremely careful when working on the transmission Always follow commonly accepted safety practices and general common sense Never risk personal injury e Do not operate the transmission or ring and pinion without proper lube and correct amount e For safe operation and to maintain the unit warranty when changing a factory installed fastener for any reason it becomes the responsibility of the person making the change to properly account for fastener grade thread engagement load tightening torque and the means of torque retention e Mounting bolts should be periodically checked to ensure that the unit is firmly anchored for proper operation e These instructions are not intended to cover all details or variations in equipment nor provide for every possible contingency to be met in connection with selection installation operation and maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the Buyer s purpose the matter should be referred to Richmond Gear In the event of the resale of any of the goods in whatever form Resellers Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreeme
8. locks 18 Notes IMPORTANT INFORMATION Please Read Carefully The following and information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your Richmond Gear product Read ALL instructions prior to operating transmission and or ring and pinion Injury to personnel transmission or ring and pinion failure may be caused by improper installation maintenance or operation It is dangerous to get under a jacked up vehicle The vehicle could slip off the jack and fall on you You could be crushed Never place any part of your body under a vehicle that is on a jack Never start or run the engine while the vehicle is on a jack If you need to get under a raised vehicle take it to a service center where it can be raised on a lift AWWARNING gt Hot oil can cause severe burns Use extreme care when removing lubrication plugs and when working close to a unit that has been in operation e Check lube level between scheduled lube changes to insure that proper lube level is maintained Inspect vent plug to insure it is clean and operating Inspect the tightness of mounting bolts misalignment of connecting shafts lube leakage excessive heating or any unusual noise or vibration e Serious personal injury may occur as a result of improperly performed maintenance adjustments or repairs e Do not attempt any of the maintenance checks or repairs described on the following pa
9. nt covering such sale The manufacturer makes no warranties or representations express or implied by operation of law or otherwise as to the merchantability or fitness for a particular purpose of the goods sold hereunder Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use In no event will the manufacturer be liable for consequential incidental or other damages Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section 2 719 of the Uniform Commercial Code the manufacturer shall have no liability to Buyer for consequential damages Resellers Buyers agree to also include this entire document including the danger warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product This information should be read together with all other printed information supplied by Richmond Gear ex RICHMOND rsiirguumuses 2215 RING amp PINIONS LIGHTENED GEARS INSTALLATION KITS REAR END LUBE INSTRUCTIONAL VIDEOS SPOOLS amp MINI SPOOLS TRANSMISSIONS TRANSMISSION FLUID QUICK CHANGE REAR ENDS CORD REELS SHOPLIGHTS EXTREME TRACTION SYSTEMS 1208 Old Norris Road PO Box 238 Liberty S C 29657 Phone 864 843 9231 Fax 864 843 2964 www richmondgear com 822 1004 A Limited Slip Differential Integral Carrier
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